DHARMSINH DESAI UNIVERSITY, NADIAD

FACULTY OF TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING

DIPLOMA CHEMICAL ENGINEERING

LABORATORY MANUAL

Mechanical Operation
(DK301)
 CONTENTS

1. Sieve Analysis

2. Sieve Efficiency

3. Jaw Crusher

4. Roll Crusher

5. Ball Mill

6. Sedimentation

7. Froth Floatation

8. Power Calculation for Agitated Vessel

9. Elutriator
 1.SIEVE ANALYSIS

AIM: To analysis the given feed mixture and find its properties like number of particles, specific
surface area and various mean diameters

REQUIREMENTS: Feed (sand) Sample, standard sieve shaker, weighing balance

THEORY:
Sieve analysis, also called the gradation test, is a practice or procedure used to analyse the
particle size distribution of a granular material.Sieve analysis reveals the size makeup of
aggregate particles–from the largest to the smallest. This phenomenon can be useful to determine
properties and strength of material, for example in case of concrete. They also have application
in aggregates used in roadway bases and in Portland cement and asphalt cement concretes.

In all procedures, it is required to shake the sample over nested sieves. The basic experiment
involves pouring sample onto the top sieve and then shaking by hand or mechanical sieve shaker.
This is done until each particle has dropped to a sieve with openings too small to pass, and the
particle is retained. The sieves are nested in order of decreasing size from the top to the bottom
and the sample, or a portion of the sample, is placed on the top sieve.

The result of the sieve analysis can be analyzed in two ways. One-Differential method, where
mass fraction retained on individual screens is plotted against particle size of material. Two-
Cumulative method, where the cumulative mass fraction on each screen is plotted against
particle size.

Mesh number is the number of square openings per linear length or inch. Aperture size is the
distance between two nearest parallel wires in screen.

PROCEDURE:

 Prepare a stack of screen as per its mesh number. Arrange smallest mesh number screen
at the top and subsequently in decreasing order.
 A representative weighed sample ( 200 gm) is poured into the top sieve which has the
largest screen openings. Each lower sieve in the column has smaller openings than the
one above. At the base is a round pan, called the receiver.
 The column is typically placed in a mechanical shaker. The shaker shakes the column,
usually for some fixed amount of time.
 After the shaking is complete the material on each sieve is weighed and note down
readings in observation table.
Graph: Cumulative mass fraction Vs Particle Size ( Differential and cumulative method of
analysis)
Results:
(i) Specific surface of mixture = _______ mm2/gm
(ii) Number of particles = ______ particles/gm
(iii)Volume surface mean diameter = ___ mm
(iv) Volume mean diameter =______ mm
(v) Mass mean diameter = _____ mm
(vi) Surface mean diameter = ____ mm
(vii) Arithmatic mean diameter = ____ mm
(viii) Length mean diameter = ____ mm
Observations:
Total weight of feed (sand) sample: _____ gm
Density of given material: _____ gm/cm3
Volume shape factor: 1
Sphericity of sand sample: 0.83

Observation Table
Mesh Aperture Avg. Mass Mass xi/Dpi xi/Dpi2 xi/Dpi3 xiDpi Cum.
No. size,mm aperture retained fraction, Mass
size,Dpi in gm xi fr.

Specific Surface of given mixture,Aw = [6/Фsρp ] *Σ(xi/Dpi )

Number of particles, Nw = [1/λvρp ] *Σ(xi/Dpi )

Volume surface mean diameter,Dvs = [1/ Σ(xi/Dpi )]

Volume mean diameter, Dv = [1/ Σ(xi/Dpi )]1/3

Mass mean diameter, Dw = Σ(xiDpi)

Arithmatic mean diameter, DA= Σ(xi/Dpi2)/ Σ(xi/Dpi3)

Length mean diameter , DL = Σ(xi/Dpi)/ Σ(xi/Dpi2)

Surface mean diameter, Ds = [1/ Σ(xi/Dpi2)]0.5

 Experiment No.-2

SCREEN EFFICIENCY

AIM: To determine efficiency of screen.

REQUIREMENTS: Feed Sample, Standard sieve shakes, weighing balance.

THEORY:

Sieving or screening has been the oldest yet most important unit operation- for industrial
separation of solid particles or as a laboratory method in sieve analysis. A stack of sieves with
decreasing mesh size is usually used. Alternatively particles can be classified in a range of fine to
coarse size as well.

But these sieves do not work ideally. An ideal sieve is the one in which after separation largest
particle in the undersize is just larger than the smallest particle in the oversize and is generally
equal to its aperture size. But generally this does not happen as oversize feed still contains some
amount of undersize particles due to logging, inefficient sieving etc.

Sieve efficiency can be found either on the basis of undersize material or oversize. Efficiency is
defined as a ratio of amount of undersize material in the undersize to the amount of undersize in
actual feed. Or it can be defined as the ratio of the amount of oversize material gained after
screening to the total amount of oversize material in the feed.

PROCEDURE:

Take 600 gm of the given feed sample and divide it into three equal parts.
Arrange sieves in the order of increasing mesh size from top to bottom
Take 200 gm of feed and put it on the top of screen
Shake the screen for around fifteen minutes and perform sieve analysis for feed sample.
Now arrange the sieves in such a manner that particular mesh size screen is at bottom
whose sieve efficiency is to be calculated. Feed the material on the top screen and do
sieve analysis. This will give oversize readings
 Similar procedure is repeated for undersize analysis but care should be taken that
particular mesh size sieve is at the top for undersize analysis.
 Record observations and do calculations
RESULT:
Efficiency of ______ mesh no Screen = _______%.
 OBSERVATION:

Mesh Aperture Average

size size aperture Feed sample Oversize sample Undersize Sample
size
Amount Weight Cumulative Amount Weight Cumulative Amount Weight Cumulative
collected fraction Weight collected fraction Weight collected fraction Weight
Fraction Fraction Fraction

CALCULATION:

Efficiency of screen.

E= (XF – XB ) (XD – XF) (1 – XB) XD

(XD –XB)2 (1 – XF) XF
 Experiment no: 3
JAW CRUSHER
AIM-To determine the energy for size reduction. Also find Rittinger’s law constant,
Bond’s law constant and Kick’s law constant

REQUIREMENTS-Jaw crusher, standard sieve shaker, balance, stopwatch

THEORY:

A jaw crusher uses compressive force for breaking of particles. This mechanical
pressure is achieved by the two jaws of the crusher of which one is fixed while the
other reciprocates. The jaw/toggle crusher consists of the following parts:

 Outer frame
 A fixed jaw (stationery jaw)
 A moving jaw (reciprocating jaw)
 Crushing chamber
Jaw crushers are the first in the process of size reduction; they reduce large uneven
shaped objects to a predetermined size. Hence they require high power consumption
and are heavy duty machines which need to be constructed robustly. The outer frame
of the jaw crusher is made of cast iron or steel. They are fitted with replaceable liners
which are made of manganese steel or Ni-hard (Ni-Cr alloyed cast iron).
The stationery jaw is a fixed immovable, vertical jaw. The other jaw is inclined and
moves back and forth in a reciprocating type of motion. Hence it is also called the
swing jaw. Jaw crushers are classified on the basis of the position of the pivoting of
the swing jaw,

1. Blake crusher-the swing jaw is fixed at the upper position

2. Dodge crusher-the swing jaw is fixed at the lower position
3. Universal crusher-the swing jaw is fixed at an intermediate position
The Blake type jaw crusher has a fixed feed area and a variable discharge area. Blake
crushers are of two types- single toggle and double toggle jaw crushers. In the single
toggle jaw crushers, the swing jaw is suspended on the eccentric shaft which leads to a
much more compact design than that of the double toggle jaw crusher. In the double
toggle jaw crushers, the oscillating motion of the swing jaw is caused by the vertical
motion of the pitman. The pitman moves up and down. The swing jaw closes, i.e., it
moves towards the fixed jaw when the pitman moves upward and opens during the
downward motion of the pitman. This type is commonly used in mines due to its
ability to crush tough and abrasive materials In the Dodge type jaw crushers, the jaws
are farther apart at the top than at the bottom, forming a tapered chute so that the
material is crushed progressively smaller and smaller as it travels downward until it is
small enough to escape from the bottom opening. The Dodge jaw crusher has a
variable feed area and a fixed discharge area which leads to choking of the crusher
and hence is used only for laboratory purposes and not for heavy duty operations.

The volume between the two jaws is called the crushing chamber. The size of this
chamber can be adjusted. The feed that is fed into the crusher gets reduced in size
between the two toggles; first in the upper part of the jaws and second when they drop
down into the lower part of the jaws where the jaws close. After sufficient size
reduction they drop out at the bottom of the machine. The jaws open and close at a
rate of 250-400 times per minute.
They are used in mines, metallurgy, road building, chemical industry etc. Jaw crusher
plant is not limited by the crushing place, and reduces high material transportation
cost.jaw crusher plant can crush materials on site. . It can be customized according to
customers’ requirement on working site, materials and particle shape.
PROCEDURE:

1. Prepare 250 gm of feed of size -1” +0.5”

2. Start the jaw crusher and find the power consumption under no load condition
with the help of energy meter and stopwatch.
3. Feed the material to a jaw crusher and crush it. Note down the time required
for crushing and reading of energy meter.
4. Do the sieve analysis of the product.
RESULTS:

Rittinger’s law constant, 𝐾𝑅 =_______

Bond’s law constant, 𝐾𝐵 =________

Kick’s law constant, 𝐾𝐾 =________

OBSERVATION TABLE:
Mesh no. Aperture size Avg diameter Mass Mass fraction Xi/Dpi
(mm) size (dpi) (mm) retained (mi) xi=mi/∑mi
(gm)

CALCULATIONS:

 Reading of energy meter for no load condition in 60 sec (P1):_____ kWh

 Convert P1 into kW
 Feed amount :_____ kg
 Time require to feed the material:_____ sec
 Feed rate : _____ kg/sec
 Reading of energy meter for loaded condition(P2) :____ kW
 Convert P2 into kW sec by dividiing ___kW with time require to feed the
material
 Actual power require for crushing , P = P2 - P1= _____ kW/sec
 Average Feed size, Dpa = (1"+0.5")/2 = ____ mm
 Average product size , Dpb = 1/(∑xi/Dpi)=______ mm
 Calculate E = P/Feed rate
 Rittinger’s law constant

1 1
𝐸 = 𝐾𝑅 [ − ]
𝐷𝑝𝑏 𝐷𝑝𝑎

KR = ______HP cm/(ton/hr)

 Bond’s law constant

1 1
𝐸 = 𝐾𝐵 [ − ] ∴ 𝐾𝐵 =______HP cm1/2/(ton/hr)
√𝐷𝑝𝑏 √𝐷𝑝𝑎
 Kick’s law constant
𝐷𝑝𝑎
𝐸 = 𝐾𝐾 𝑙𝑛 ( ) ∴ 𝐾𝐾 =______HP/(ton/hr)
𝐷𝑝𝑏
 EXPERIMENT NO:4
ROLL CRUSHER

AIM:To determine 1)Angle of Nip 2)Reduction ratio 3)Actual capacity 4)Theoretical

capacity 5)Ribbon factor 6)Efficiency 7) constants of Kick's law ,Rittinger's law and
Bond's law for roll crusher

REQUIREMENTS: Roll crusher, feed sample, sieve shaker, stopwatch

THEORY:

PRINCIPLE:
Size reduction is achieved by compression.The roll crusher will be broken material
feeding the mouth fall between two rollers, extrusion, finished product material nature.
CONSTRUCTION: Roll crusher is mainly supported by rollers, bearings, clapping,
adjusting device and drive unit components. In roll crusher two heavy metal rolls of same
diameter laid side by side each other in horizontal position. The speeds of both rolls are
same. One shaft moves in fixed bearing and other in moveable bearing. The clearance
between can be adjusted accordingly to the size of speed.
The material fed to roll crusher is reduced in size by compression and will be discharge
from bottom. The machine is protected by spring loading (i.e. by mounting the bearing of
one roll shaft against coiled led) against due to damage due to tramp and very hard
material feed.
The speed of rolls varies from 50-300 rev./min. Crushing rolls are secondary crusher
accepting feed 12 to 75 mm in size.
Mclanhan double roll crusher provide a 4:1 reduction ratio are typically used as
secondary or tertiary crushers for materials like limestone, gypsum, coal, coke,
quicklime, glass, brick, bauxite and other solid material.

WORKING: The material to be crushed is fed from the top or the crusher. As the rolls
rotate, the material is in touch with them and gets reduced in size by compression and
leaving from the bottom of crusher.
 r2

r1

b
Figure shows an idealized system where a spherical or cylindrical particle of radius r2 is
being fed to crushing rolls of radius r1. 2 is the Angle of Nip, the angle between the two
common tangents to the particle and each of the rolls, and 2b is the distance between the
rolls. It will be seen from the geometry of the system that the angle of nip is given by:
(r1 + b) / (r2 + r1) = cos
For steel rolls, the Angle of Nip will be not greater than about 32 o.
Crushing rolls are extensively used for crushing oil seed and in the gunpowder industry
and are also suitable for abrasive materials. They are simple in construction and do not
give a large percentage of fines.
1. Theoretical capacity=(2 *  *n * d * b* r1* p* 60)
2. Actual capacity=weight of feed/crushing time
3. Ribbon factor=Actual capacity/theoretical capacity.

PROCEDURE:
1. Measure the diameter of the rolls and clearance between the rolls.
2. Measure the power and rpm of roll under no load condition.
3. Prepare 500 gm of the feed sample of -0.5 + 0.25 and feed into the roll crusher. Note
the time taken for crushing the feed.
4. Measure the rpm of roll under loading conditions.
5. Perform sieve analysis of the product.

RESULTS:
1) Angle of nip =_______
2) Actual capacity =______
3) Theoretical capacity =______
4) Efficiency of roll crusher =_______
5) Reduction ratio =______
6) Specific surface ratio =______
7) Rittinger’s law constant =______
8) Bond’s law constant =______
9) Kick’s law constant =______
OBSERVATION:
- Diameter of roll (D) =_____cm
- Radius of roll(R) = _____cm
- Diameter of feed particles (2R) = (0.5+0.25)/2= _____cm
- Clearance of feed two rolls (2d)=_____cm
- Breadth of roll (b) = _____cm
- RPM of roll (N) = _____RPM
-
OBSERVATION TABLE:

Mesh no. Aperture size Average Mass mass fraction

(mm) particle dia. retained xi=mi=/∑mi Xi/Dpi
(Dpi) (mm) (mi)(gm)

CALCULATION:

 Reading of energy meter for no load condition in 60 sec (P1):_____ kW

 Convert P1 into kW/sec
 Feed amount :_____ kg
 Time require to feed the material:_____ sec
 Feed rate : _____ kg/sec
 Reading of energy meter for loaded condition(P2) :____ kW
 Convert P2 into kW sec by dividiing ___kW with time require to feed the material
 Actual power require for crushing , P = P2 - P1= _____ kW/sec
 Average Feed size, Dpa = (1"+0.5")/2 = ____ mm
 Average product size , Dpb = 1/(∑xi/Dpi)=______ mm
 Calculate E = P/Feed rate
 Rittinger’s law constant

1 1
𝐸 = 𝐾𝑅 [ − ]
𝐷𝑝𝑏 𝐷𝑝𝑎
 KR = ______HP cm/(ton/hr)

 Bond’s law constant

1 1
𝐸 = 𝐾𝐵 [ − ] ∴ 𝐾𝐵 =______HP cm1/2/(ton/hr)
√𝐷𝑝𝑏 √𝐷𝑝𝑎
 Kick’s law constant
𝐷𝑝𝑎
𝐸 = 𝐾𝐾 𝑙𝑛 ( ) ∴ 𝐾𝐾 =______HP/(ton/hr)
𝐷𝑝𝑏
 Angle of nip = 2α
Where, cosα=(R+d)/(R+r)
 Diameter of product=1/(∑xi/Di)=_______cm
 Reduction Ratio = Size of feed / Size of product
 Theoretical capacity Q = 240*3.14*R*N*b*d
=_________cm3/min
 Actual capacity =Feed(kg)/time for crushing
=_________kg/sec
=_________cm3/sec
 Ribbon factor = Actual capacity / Theoretical capacity
=__________
 Efficiency = 100*Ribbon factor
 Experiment No.-5

BALL MILL

AIM: To determine the optimum speed for the given maximum new surface area generated for a
given feed and also determine critical speed of Ball Mill

APPARATUS: Ball Mill, Standard Sieves, Stop Watch, Feed material, weighing Balance, Sieve
Shaker

THEORY:
A ball mill is a type of grinder used to grind and blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics and selective laser sintering.
A ball mill works on the principle of impact: size reduction is done by impact as the balls drop from
near the top of the shell.
A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell may be
either horizontal or at a small angle to the horizontal. it is partially filled with balls. The grinding
media is the balls, which may be made of steel (chrome steel), stainless steel or rubber. The inner
surface of the cylindrical shell is usually lined with an abrasion-resistant material such as
manganese steel or rubber. Less wear takes place in rubber lined mills, such as the Sepro tyre drive
Grinding Mill. The length of the mill is approximately equal to its diameter.
In case of continuously operated ball mill, the material to be ground is fed from the left through 60°
cone and the product is discharged through a 30° cone to the right. As the shell rotates, the balls are
lifted up on the rising side of the shell and then they cascade down (or drop down on to the feed),
from near the top of the shell. In doing so, the solid particles in between the balls are ground and
reduced in size by impact.

PROCEDURE:
1. Take 250 gm feed having size -7+10 mesh number screen.
2. Calculate critical and optimum speed of ball mill.
3. Before starting ball mill, make sure that all steel balls and feed materialsare in the cylinder.
Also ensure the opening of ball mill tightly closed with plate. Start the ball mill and fix
optimum speed of the mill. Rotate ball mill for 30 min operating time.
4. Stop the ball mill and collect all the product from mill.
5. Do sieve analysis of the product and note down the readings in observation table.

RESULTS:

1. Critical speed of ball mill= rpm

2. Optimum speed of ball mill= rpm

3. Specific surface area= mm2/gm

OBSERVATIONS:

1. Radius of ball mill (R)= _______ cm

2. Radius of ball (r)= _______ cm

3. Density of particle= _________ gm/ cm3

4. Shape factor=

5. Number of balls=

6. g= 981 cm/ sec2

OBSERVATION TABLE:

Mesh Aperture Avg Diameter Mass Retained Mass Fraction, xi/Dpi

Number Size (mm) (Dpi)(mm) (mi) (gm) xi=mi/∑mi

CALCULATIONS:

1. Critical Speed

Nc=(1/2∏)*(g/R-r)1/2 = _________ rpm

2. Operating Speed

=0.6*Nc= _______ rpm

3. Specific surface of mixture

Aw = (6/⦱s ƍP)*∑(xi/Dpi) = ________ mm2/gm

 EXPERIMENT NO.6

SEDIMENTATION

AIM: To determine file settling characteristics of CaCO3 slurry and to calculate the
area of the continuous thickener having solid handling capacity 1000kg/day.

Apparatus: 250ml beaker, measuring cylinder, CaCO3 etc.

THEORY: The separation of solids from suspension in liquid by gravity settling is

called sedimentation.

Free settling refers to be the process wherein the fall of the particle in a
gravitational field through a stationary fluid is not affected by the walls of
container and other particles.

Hindered settling: When the concentration of particle in suspension is large,

particles will be so close to each other that the surrounding particles will interface
with the motion of other individual particles. If the fall of particle through
stationary fluid is impeded by the other particles, the process is called hindered
settling.

The mechanisms of settling may be best described by batch settling test in a glass
cylinder.
These are several stages in the settling of a flocculated suspension, and different
zones are formed as sedimentation proceeds. At first, the solid is uniformly
distributed in the liquid Fig(a). The total depth of suspension is . After a short
time, the solids have settled to give a zone of clear liquid, zone A in Fig(b), and a
zone D of settled solids. Above zone D is a transition layer, zone C, in which the
solids content varies from that in original pulp to that in zone D. In zone B, the
concentration is uniform and equals to the original concentration, since the
settling rate id the same throughout this zone. The boundaries between zones D
and C and between C and B may not be distinct, but the boundary between zones
A and B is usually sharp.

As settling continues, the heights of each zone vary. The heights of zones D
and A increases at the expense of that of zone B while that of C remains constant.
After further settling, zones B & C disappear, all the solids appear in zone D.

Equipment for sedimentation: Thickeners industrially this process is conducted

on a large scale in equipment called thickeners. For relatively fast-settling
particles, a batch settling tank or continuous settling cone may be adequate.

PROCEDURE: ( Using Kynch theory of sedimentation)

1) Take the two graduated cylinders of 250ml capacity. Prepare slurry by

putting 20gm CaCO3 in 250ml water (8% slurry).
2) Note initial height up to which solution is filled and take it as at time
note down settling time for every 1cm decrease from and make a
column for cumulative time required for every 1cm decrese in height.
3) Plot graph of height Vs Cumulative time .[fig1]
4) Draw tangent to each point on the graph. Each tangent will intersect at Y
axis and mark it as .[fig1]
5) According to kynch theory, use the below equation to find for every
point.

6) Find slope of tangent to every point in the graph which gives us

velocity .
7) Plot graph of . The curve shown in [fig2] will ensure that
calculations uptill now are correct.
8) The tangents from first and last reading in the graph will intersect at a
point and make an angle suppose 2Ө. Draw an angle bisector which will
intersect the original curve at a point. The co-ordinate at Y axis of this point
will give us .[fig1]
9) Now again making use of kynch theory we get using this
find (which is under layer concentration).
10) Make a column for . Plot a graph of and we will

get a curve as shown in [fig3].

11) Using the graph find .

12) Using this minimum value and design capacity of thickener find
area.
Graph:

I. Height( ) Vs. Cumulative Time( ) [fig1]

II. Velocity( ) Vs. Concentration( ) [fig2]
III. Vi/[(1/Ci)-(1/Cu)] Vs. [fig3]
 Observation:

I. Initial height ( =_______

II. Initial Concentration( ) =_______
III. Given thickener capacity =__1 ton per day_____

Sr Height Time [(1/Ci)-(1/Cu)] Vi/[(1/Ci)-(1/Cu)]

No.

Calculation: find A(area of given thickener) by following equation,

L0C0/A=Vi/[(1/Ci)-(1/Cu)] min

Result:

Area of given thickener=______m2

 EXPERIMENT 7

FROTH FLOTATION CELL

Aim: To study effect of different frothing agent in the recovery of given sample in flotation cell

Equipment: Flotation cell , Pine oil , Water , ore sample, detergent powder , 400 mesh
number screen.

Theory:
Froth flotation is a process for separating minerals from gangue by taking advantage of
difference in their hydrophobicity. Flotation is devided in three stages ;
(1) Roughing: The first stage is called roughing which concentrate. The objective is to
remove the maximum amount of valuable minerals at as coarse a particle size as particle.
The finer an ore is ground , the greater the energy that is required , so it makes sence to
fine grind only those particle that need fine grind only those particles that need fine
grounding. Complete libration is not required for rougher flotation , only sufficient
libration to release enough gangue from the valuable mineral to get a high recovery.
(2) Cleaning: The rougher concentrate is normally subjected to further stages of flotation to
reject more of the undesirable minerals that also reported to the froth , in a process is
known as cleaning. The product of cleaning is known as the cleaner concentrate. The
objective of cleaning is to produce as high a concentrate grade as possible.
(3) Scavenging: the step is applied to the rougher tailings. The objective is to recover any of
the target minerals that were not recovered during initial roughing stages. This might be
achieved by changing the flotation conditions to make them more rigorous, or some
secondary grinding to provide further libration. Similarly the cleaning step is followed by
a scavenging step performed on the cleaner tailings.
Froth flotation is depends on the selective adhesion of air bubbles to mineral
surface in a mineral/water slurry. The air bubbles will attach to more hydrophobic particles. The
attachment of the bubbles to the interfacial energies between the solid, liquid and gas phases.
This is determined by Younge-dupre.
Procedure:
(1) Preapare slurry by mixing water and given powder taken about 10gms in the flotation
machine.
(2) Three-four drops of the pine oil are added and the agitator of the cell is started. Froth is
formed when air is passed through the slurry.
(3) The froth is the collected on a 400 mesh screen. The froth is dried in a dryer and the
weight of the dried powder is measured.
(4) Repeat the experiment with 6 and 9 drops of oil and tabulate the results.
 Observation:
 Total weight of the sample=_______ grams.
 Observation Table:
Sr no. Weight of the Amount of Weight of dry % Recovery
sample (gms) pine oil ore sample

% Recovery = [Wt. of powder recovered/Wt. of powder taken ] *100

 POWER CONSUMPTION IN AGITATED VESSEL
EXPERIMENTAL MANUAL
Aim:
To determine the power number for an agitated vessel system using given set of impeller with
baffled/unbaffled mixing tank.

To relate the power number and Reynolds number in an agitated system

Apparatus description:
The set up consist of a SS 304 tank with insulation from outside. The different type of impeller
with variable speed drive is provided. The four number of baffles provided inside the tank which
is removable.

Theory:

Axial flow impeller (left) and radial flow impeller (right).

Impellers in agitated tanks are used to mix fluids or slurry in the tank. This can be used to
combine materials in the form of solids, liquids and gas. Mixing the fluids in a tank is very
important if there are gradients in conditions such as temperature or concentration.
There are two types of impellers, depending on the flow regime created (see figure):

 Axial flow impeller

 Radial flow impeller
Radial flow impellers impose essentially shear stress to the fluid, and are used, for example, to
mix immiscible liquids or in general when there is a deformable interface to break. Another
application of radial flow impellers are the mixing of very viscous fluids.
Axial flow impellers impose essentially bulk motion, and are used on homogenization processes,
in which increased fluid volumetric flow rateis important.
Impellers can be further classified principally into three sub-types

 Propellers
 Paddles
 Turbines
All these can be discussed immediately after example.

The Power number, Np, is given as:

P
Np = ρN3d5

where P is the power utilized for agitation ρ, the _uid density, N, the impeller speed and
impeller diameter. The Reynolds number NRe, for an agitated system is given by:
NRe = ρNd2
µ
Where, µ is the liquid viscosity.
Procedure:

 Check the bottom valve should be closed.

 Place the given water or viscous liquid in a mixer system and agitate it by setting the
impeller speed to a particular value.

 Also, measure the impeller speed and impeller diameter.

 Vary the agitation speed using the regulator.

 Find the Power number and the Reynolds number for each run.

 Represent the relationship between Power number and Reynolds number, graphically.

 Repeat whole procedure by using different types of impeller, and also in baffled and
unbaffled condition.

FOR BAFFLED CONDITION

Observations:
 Viscosity of liquid(water) (µ) = 0.890 cp
 Density of liquid (ρ) = 1000 kg/m3
 No. of baffles at tank wall = 4
 Speed of agitator (n) = 1000 rpm = 16.66 rps
 Diameter of agitator = 100 mm = 0.1 m
 Type of agitator = Six Blade Turbine Agitator
 Gravitational constant (gc) = 9.81 m/s2

Observation table:

Sr No. Rpm Ampere (I) Voltage (V)

1
2
3
4
5
6
7
8
9
10
Theoretical Calculations:

The Reynolds number NRe, for an agitated system is given by:

NRe = ρNDa
2
µ
=

Where,
µ = liquid viscosity.
ρ = liquid density
N = impeller speed
Da = impeller diameter

Now find NP from graph 9.12 McCabe and Smith (5th Ed.)
To see which line of the graph will use
Find S1, S2, S3, S4,

S1 = Da/Dt

= 100/300
= 0.33

S4 = W/Da

= 20/100

= 0.2

S2 = E/Dt

= 30/300
= 0.1

S3 = L/Da

= 40/100
= 0.4

S5 = J/Dt

= 25/100
= 0.25

S6 = H/Dt

= 300/300
= 0.1
Where

Da = diameter of agitator = 100 mm

Dt = diameter of tank = 300 mm
W = width of agitator blade = 20 mm
E = clearance between agitator and bottom of tank = 30 mm
L = length of blade = 40 mm
J = width of baffle = 25 mm
H = height of the liquid = 300 mm

Now, see the value of Np from the graph of Np vs. NRe (figure 9.12 McCabe and Smith)

Np = ____ (From granph)

Now,
P = Np*ρN3Da5

= _____ KW

Where,
P = power utilized for agitation
ρ = liquid density
N = impeller speed
Da = impeller diameter
Np = power number
Practically calculations:
P = V*I
= 240 * 0.8
= 192 Watt
= 0.192 KW
Where
P = power utilized for agitation
V = voltage
I = current (amp)

The Power number, Np , is given as:

Pgc
Np = ρN3Da5

= 0.192*9.81
------------------------
1000*(16.66)3 *(0.1)5

=0.040
Where,
P = power utilized for agitation
ρ = liquid density
N = impeller speed
Da = impeller diameter

The Reynolds number NRe, for an agitated system is given by:

NRe = ρNDa2
µ
= 1000*16.66*(0.1)2
---------------------------
0.890
= 187.2
FOR UNBAFFLED CONDITION

Observations:
 Viscosity of liquid(water) (µ) = 0.890 cp
 Density of liquid (ρ) = 1000 kg/m3
 Speed of agitator (n) = 1000 rpm = 16.66 rps
 Diameter of agitator = 100 mm = 0.1 m
 Type of agitator = Six Blade Turbine Agitator
 Gravitational constant (gc) = 9.81 m/s2

Observation table:

Sr No. Rpm Ampere (I) Voltage (V)

1
2
3
4
5
6
7
8
9
10

Theoretical Calculations:

The Reynolds number NRe, for an agitated system is given by:

Nre = ρNDa
2
µ
=
Where,
µ = liquid viscosity.
ρ = liquid density
N = impeller speed
Da = impeller diameter
For unbaffled condition the curve D will be applied from the graph of Np vs. NRe (figure 9.12
McCabe and Smith)

For unbaffled condition the value of Np must be multiplied by Nfrm

Froud number,

Nfr = n2Da/g

= (16.66)2 * 0.1 / 9.81

= 2.82

The exponent m

m = a – log10 Nre

-----------------

= 1.0 - log10 Nre / 40

= - 0.0318

From table 9.1 McCabe and Smith the constant a and b are substituted in equation

a = 1.0

b = 40

now, Np from graph 9.12 curve D for unbaffled

Np = 3.8

So, corrected Np,corrected = Np * Nfrm

Now,
P = Np,corrected*ρN3Da5

= ___ KW
Practically calculations:
P = V*I
= 240 * 0.7
= 168 Watt
= 0.168 KW
Where
P = power utilized for agitation
V = voltage
I = current (amp)

The Power number, Np , is given as:

Pgc
Np = ρN3Da5

=
Where,
P = power utilized for agitation
ρ = liquid density
N = impeller speed
Da = impeller diameter

The Reynolds number NRe, for an agitated system is given by:

NRe = ρNDa2
µ
=
 Experiment no.9
Elutriator
Aim: To find percentage recovery of sand from mixture of gravel and sand by
using elutriation method.
Equipment: Elutriator.
Requirements: Water, sand (35gm) and gravel (15gm) mixture.
Theory:
Principle:Elutriation is a process for separating particles based on their size, shape
and density, using a stream of gas or liquid flowing in a direction usually opposite
to the direction of sedimentation.The smaller or lighter particles rise to the top
(overflow) because their terminal sedimentation velocities are lower than the
velocity of the rising fluid. This method is mainly used for particles smaller than
1 μm.
Working: Material may be separated by means of an elutriator, which consists of a
vertical tube up which fluid is passed at a controlled velocity. When the particles
are introduced, often through a side tube, the smaller particles are carried over in
the fluid stream while the larger particles settle against the upward current. If one
starts with low flow rates, small less dense particle attain their terminal velocities,
and flow with the stream. The particle from the stream is collected in overflow and
hence will be separated from the feed. Flow rates can be increased to separate
higher size ranges. Further size fractions may be collected if the overflow from the
first tube is passed vertically upwards through a second tube of greater cross-
section, and any number of such tubes can be arranged in series.
Usages: It is used in mineral processing for size classification. The elutriation dust
value is a usual measure for quantification of dust, generated by testing wherein
mechanical forces such as vibration are applied to granules of e.g. a detergent
agent.
Procedure:
1) Take feed sample containing 35gm sand and 15gm gravel mixture.
2) Find K values for lighter and heavier particle to find terminal velocity.
3) Find terminal velocities for the heavier and lighter particle using Newton’s
law or Stock’s law depending on calculated K values.
4) Find flow rate for heavier and lighter particle.
5) Set flow rate of fluid(water) in between flow rate of heavier and lighter
particle for desired separation.
6) Feed given sample for separation in elutriator. Collect the samples from the
bottom of elutriator -1 and elutriator-2.After completion of process find
percentage recovery of sand(lighter particle) from top of each elutriator.
Observations:

A=Heavier particle (gravel) B=Lighter particle (sand)

Avg. diameter of A ( )=2.43 mm Avg. diameter of B( ) =0.2mm

Density of A( )=2350 kg/m3 Density of B( )=1600 kg/m3

Diameter of pipe=D

Density of fluid (water) =1000 kg/m3

Viscosity of fluid (water) =0.001 kg/(m*s)

Observation table:

Feed Elutriator 1 Elutriator 2

A(gravel) 15gm 14gm(bottom) -
B(sand) 35gm 2gm(top) 30gm

Calculations:

1) Area of pipe cross-section=(Ӆ/4)D2

2) K value

3) Terminal velocities
1) Stock’s law

2) Newton’s law
find Cd using this
 4) Flow rate of A and B

5) Operating flow rate of fluid

Q=
6) % Recovery of sand in elutriator 1
=(sand in top of elutriator 1/sand in feed)*100
% Recovery of sand in elutriator 2
=(sand in top of elutriator 2/sand in feed)*100
7) Total % Recovery of sand
=(% Recovery of sand in elutriator 1+ % Recovery of sand in elutriator)

Result:

Total % Recovery of sand is =________%